Table of Contents
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RS – Multi-Stage, Centrifugal Pump
Part Number: _______________________________________
Serial Numbers: _____________________________________
These operating instructions contain fundamental information and precautionary notes. Please read the manual
thoroughly prior to installation of unit, electrical connection and commissioning. It is imperative to comply with all
other operating instructions referring to components of individual units.
This manual shall always be kept close to the unit's location of operation or directly on the pump set.
INSTALLATION, OPERATION AND
MAINTENANCE INSTRUCTIONS
I-280
280 – 16.03.EN
Inch Units
For Units Built After December 2015
ATEX REV.0
Inch Units
ATEX
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Table of Contents
Related Manuals for Carver Pump RS Series
Summarization of Contents
General Description and Safety Precautions
General Information
Overview of pump engineering and intended service life.
ATEX Directive 94/9/EC
Compliance requirements for potentially explosive atmospheres.
Disclaimer
Statement regarding manual accuracy and completeness.
Personnel Qualification and Training
Requirements for qualified personnel performing unit tasks.
Pump Identification
Locating and recording pump type, size, and serial number.
Safety
Safety Precautions
Essential guidelines for safe installation, operation, and maintenance.
Summary of Safety Marking
Explanation of safety symbols and warnings used in the manual.
Products Used in Potentially Explosive Atmospheres
Measures to prevent hazards in explosive environments.
Scope of Compliance
Guidance on using equipment appropriate for the specific atmosphere.
Safety (Continued)
Safety Awareness
Importance of adhering to safety instructions and regulations.
Safety Instructions for the Operator/User
Directives for safe operation, including guards and leak management.
Safety Instructions for Maintenance, Inspection and Installation Work
Procedures for safe maintenance, inspection, and installation tasks.
Non-Compliance with Safety Instructions
Consequences of not following safety guidelines, including injury and forfeiture of rights.
Unauthorized Modification and Manufacture of Spare Parts
Guidelines on modifications and use of authorized spare parts.
Safety (Continued)
Unauthorized Modes of Operation
Adhering to designated use and nameplate limits to maintain safety.
Explosion Protection
Essential measures for ensuring explosion protection in hazardous areas.
Unit Fill
Ensuring the system is completely filled with fluid to prevent explosive atmospheres.
Marking
Interpretation of ATEX equipment marking and its components.
Checking the Direction of Rotation
Procedure to safely verify pump rotation direction, especially in ATEX areas.
Pump Operating Mode
Correct procedures for starting and operating the pump.
Safety (Continued)
Temperature Limits
Understanding and adhering to temperature classes for ATEX compliance.
Safety (Continued)
Maintenance
Requirements for maintaining the pump for safe ATEX operation.
General Safety Instructions
General safety practices applicable to electrical and mechanical work.
Equipment Description
Discharge Case
Description of the discharge case and its components.
Impeller
Description of enclosed impellers and their installation.
Diffuser
Description of diffusers and their role in interstage casings.
Shaft
Description of the pump shaft and its protection.
Ball Bearings
Details on ball bearings used in the bearing frame.
Bearing Frame
Function and features of the bearing frame.
Base
Description of the grout-able base for pump support.
Mechanical Seal
Information on mechanical seals and their installation.
Interstage Case
Description of interstage casings and their assembly.
Effects of Fluids
Net Positive Suction Head (NPSH)
Explanation of NPSH requirements and availability for pump operation.
Changing Pump Speed
How pump speed affects capacity, head, and power consumption.
Effects of Viscosity
Impact of liquid viscosity on pump performance and handling.
Effects of Specific Gravity
Influence of specific gravity on pump discharge pressure and driver load.
Technical Data
Noise Levels
Information regarding operational noise levels and required protection.
Axial Impeller Alignment Control Dimensions
Table providing dimensions for axial impeller alignment.
Seal Chamber Dimensions
Standard dimensions for seal chambers based on pump size.
Key Mechanical Data
Table of critical mechanical data for pump models.
Permissible Nozzle Loads
Limits for forces and moments on pump nozzles.
Inspection and Storage
Inspection
Procedures for inspecting the pumping unit upon receipt.
Packing for Return
Guidelines for safely packing the unit for return and required documentation.
Storage of Pump
Recommendations for storing the pump to prevent damage.
Installation
Location
Criteria for selecting an appropriate installation site for the pump.
Handling
Safe procedures for moving and lifting the pumping unit.
Foundation
Requirements for a solid and stable foundation for the pump assembly.
Installation (Continued)
Leveling of Unit
Steps for accurately leveling the pump and motor assembly.
Grouting
Procedures for properly grouting the unit to the foundation.
Coupling Alignment
Soft Foot
Identifying and correcting soft foot conditions for proper alignment.
Shaft Alignment Measurement Methods
Overview of methods like Laser Alignment for shaft alignment.
Checking Coupling Alignment
Detailed steps for verifying axial, parallel, and angular alignment.
Pre-Installation Procedures
Pre-Installation Procedures
Steps to perform before connecting piping and finalizing installation.
Auxiliary Piping and Gauges
Auxiliary Piping Connections and Gauges
Connecting auxiliary lines such as gauges and drains.
Direction of Rotation
Direction of Rotation
Verifying correct pump rotation direction indicated on the bearing frame.
Operation
Pre-Start Cautions
Critical checks before activating the pumping unit, including personnel safety.
Priming
Procedures for priming the pump for positive and negative suction head systems.
Operation (Continued)
Starting the Pump
Steps for safely starting the pump, including valve positions and cooling.
Turbine Applications
Specific considerations for pumps used in turbine applications.
Minimum/Maximum Flow Calculation
Formulas for calculating minimum and maximum flow rates.
Operating Checks
Verifying pump operation, including vibration, flow, pressure, and power.
Stopping the Pump
Procedures for safely stopping the pumping unit.
Indefinite Shutdown
Indefinite Shutdown
Procedures for safely shutting down the pump for extended periods.
Troubleshooting Operating Problems
Troubleshooting Operating Problems
Guide to identifying and resolving common pump operational issues.
Maintenance
Daily Inspection
Routine visual checks and operational parameter monitoring.
Weekly Inspection
Checks including power readings, discharge pressure, and vibration.
Monthly Inspection
Checks for coupling alignment and foundation bolts.
Semi-annual Inspection
Checks for oil changes and coupling alignment due to foundation settling.
50/300 Hour Service
Recommended oil change intervals after initial operation.
1000 Hour Service
Routine oil change intervals after initial services.
20,000 Hour Overhaul
Schedule for complete pump overhaul and seal replacement.
Lubrication of Pump Bearings
Lubrication of Pump Bearings
Instructions for filling and maintaining oil levels in the bearing frame.
Lubrication of Motor Bearings
Lubrication of Motor Bearings
Reference to motor manufacturer's instructions for bearing lubrication.
Torque Values
Torque Values
Recommended torque values for fasteners and bearing jam nuts.
Service and Repair
Preparations for Disassembly of Pump
Steps to take before starting pump disassembly, including safety and cleaning.
Disassembly of Pump with Standard Sleeve Bearing
Disassembly of Pump with Standard Sleeve Bearing
Step-by-step instructions for dismantling pumps with standard sleeve bearings.
Disassembly of Pump with Optional Mechanical Seals
Disassembly of Pump with Optional Mechanical Seals
Step-by-step instructions for dismantling pumps with optional mechanical seals.
Parts Inspection
Parts Inspection
Procedures for cleaning, inspecting, and replacing parts after disassembly.
Reassembly of Pump with Standard Sleeve Bearing
Reassembly of Pump with Standard Sleeve Bearing
Step-by-step instructions for reassembling pumps with standard sleeve bearings.
Replacement of Wear Ring
Suction Case Wear Ring
Instructions for replacing the first stage wear ring in the suction case.
Diffuser Wear Ring
Instructions for replacing wear rings in the diffuser.
Replacement of Wear Ring (Continued)
Interstage Case Wear Ring
Instructions for replacing wear rings in the interstage case.
Motor Maintenance
Motor Maintenance
Reference to manufacturer's instructions for motor maintenance.
Check Valve Maintenance
Check Valve Maintenance
Reference to manufacturer's instructions for check valve maintenance.
Parts Lists and Drawings
Parts Lists and Drawings
Section containing spare parts lists and assembly diagrams.
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